U.S. patent number 5,460,672 [Application Number 08/233,469] was granted by the patent office on 1995-10-24 for apparatus and method for joining a plurality of textile webs together in side-by-side relation.
This patent grant is currently assigned to Petco, Inc.. Invention is credited to Jerry M. Mallonee.
United States Patent |
5,460,672 |
Mallonee |
October 24, 1995 |
Apparatus and method for joining a plurality of textile webs
together in side-by-side relation
Abstract
An apparatus for joining a plurality of textile webs together in
side-by-side relation includes a feeder for positioning a first
textile web overlying a second textile web and advancing the
textile webs along a predetermined path of travel, an ultrasonic
horn and anvil for forming a relatively narrow flexible joint
between the textile webs by heat fusing together adjacent portions
thereof, and an unfolding frame for unfolding the textile webs
about the joint so that the textile webs lie in a common plane to
define the relatively wide textile fabric. More particularly, in
order to form the convolute roll of the relatively wide textile
fabric, the apparatus also preferably includes a driven take-up
spindle positioned downstream from the unfolding frame to wind the
relatively wide textile fabric into successive convolute wound
layers. Accordingly, the relatively narrow flexible joint is thus
folded to lie flat between successive layers so that the successive
convolute wound layers define a cylindrical convolute roll being
devoid of a substantial bulge at the joint. An associated method is
also disclosed.
Inventors: |
Mallonee; Jerry M. (Hickory,
NC) |
Assignee: |
Petco, Inc. (Newton,
NC)
|
Family
ID: |
22877376 |
Appl.
No.: |
08/233,469 |
Filed: |
April 26, 1994 |
Current U.S.
Class: |
156/73.4;
156/184; 156/301; 156/302; 156/324; 156/544; 156/554; 156/580.1;
242/520; 493/410 |
Current CPC
Class: |
B29C
65/08 (20130101); B29C 66/43 (20130101); B29C
66/435 (20130101); B29C 66/7294 (20130101); B29C
65/02 (20130101); B29C 65/743 (20130101); Y10T
156/1097 (20150115); Y10T 156/1095 (20150115); Y10T
156/1715 (20150115); B29C 66/1122 (20130101); B29K
2313/00 (20130101); B29C 66/71 (20130101); Y10T
156/1739 (20150115); B29C 66/71 (20130101); B29K
2023/12 (20130101); B29C 66/71 (20130101); B29K
2067/00 (20130101) |
Current International
Class: |
B29C
65/00 (20060101); B29C 65/08 (20060101); B29C
65/74 (20060101); B32B 031/16 () |
Field of
Search: |
;156/73.1,73.4,184,301,302,324,544,580.1,580.2,157,159,554
;493/409,410,411 ;242/520,535 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Simmons; David A.
Assistant Examiner: Sells; J.
Attorney, Agent or Firm: Allen, Dyer, Doppelt, Franjola
& Milbrath
Claims
That which is claimed:
1. A method for forming a convolute roll of a relatively wide
textile fabric by joining together a plurality of textile webs in
side-by-side relation, each of the textile webs comprising heat
fusible nonwoven textile material, said method comprising the steps
of:
positioning a first textile web overlying a second textile web
while advancing the first and second textile webs along a
predetermined path of travel;
forming a relatively narrow flexible joint between the first and
second textile webs by heat fusing together adjacent portions
thereof as the textile webs are moved along the predetermined path
of travel;
unfolding the thus joined first and second textile webs about the
joint so that the first and second textile webs lie in a common
plane to define the relatively wide textile fabric and so that the
relatively narrow flexible joint extends outwardly from adjacent
portions of the relatively wide textile fabric; and
winding the relatively wide textile fabric into successive
convolute wound layers with the relatively narrow flexible joint
folded to lie flat between successive layers so that the successive
convolute wound layers define a cylindrical convolute roll being
devoid of a substantial bulge at the joint.
2. A method according to claim 1 wherein the step of winding the
relatively wide textile fabric comprises winding the successive
convolute wound layers of the textile fabric with variations in
axial alignment among the layers so that the relatively narrow
joint is offset throughout the successive convolute wound
layers.
3. A method according to claim 1 wherein the first and second
textile webs have a predetermined thickness, and wherein the step
of forming the joint further comprises pressing together the
adjacent portions of the first and second textile webs so that the
joint has a thickness less than the predetermined thickness of the
textile webs.
4. A method according to claim 3 further comprising the step of
trimming predetermined portions of heat fused textile material at
the joint so that the joint has a relatively narrow width of less
than about five times the predetermined thickness of the textile
webs.
5. A method according to claim 1 wherein the step of forming the
joint comprises ultrasonically welding the adjacent portions of the
first and second textile webs.
6. A method according to claim 1 wherein the step of positioning
the first and second textile webs further comprises relatively
positioning the first and second textile webs so that respective
first longitudinal edges of the first and second textile webs are
generally aligned with each other.
7. A method according to claim 6 further comprising the steps
of:
positioning a third textile web on the second textile web so that a
longitudinal edge of the third textile web is generally aligned
with a second longitudinal edge of the second textile web;
forming a second relatively narrow flexible joint between the
second and third textile webs by heat fusing together adjacent
portions of the second and third textile webs; and
wherein said unfolding step further includes unfolding the second
and third webs about the second joint so that all of the webs lie
in a common plane to further define the relatively wide textile
fabric.
8. An apparatus for forming a convolute roll of a relatively wide
textile fabric by joining together a plurality of textile webs in
side-by-side relation, each of the textile webs comprising heat
fusible nonwoven textile material, said apparatus comprising:
feeder means for positioning a first textile web overlying a second
textile web and advancing the textile webs along a predetermined
path of travel;
welding means positioned along the predetermined path of travel for
forming a relatively narrow flexible joint between the first and
second textile webs by heat fusing together adjacent portions
thereof;
an unfolding frame positioned downstream from said welding means
for unfolding the first and second textile webs about the joint so
that the textile webs lie in a common plane to define the
relatively wide textile fabric and so that the relatively narrow
flexible joint extends outwardly from adjacent portions of the
relatively textile wide fabric; and
take-up means positioned downstream from said unfolding frame to
wind the relatively wide textile fabric into successive convolute
wound layers with the relatively narrow flexible joint folded to
lie flat between successive layers so that the successive convolute
wound layers define a cylindrical convolute roll being devoid of a
substantial bulge at the joint.
9. An apparatus according to claim 8 wherein said take-up means
comprises means for winding successive convolute wound layers of
the textile fabric with variations in axial alignment among the
layers so that the relatively narrow joint is offset throughout the
successive convolute wound layers.
10. An apparatus according to claim 8 wherein all of the textile
webs have a same predetermined thickness, and wherein said welding
means comprises means for pressing together the adjacent portions
of the first and second textile webs so that the joint has a
thickness less than the predetermined thickness of the textile
webs.
11. An apparatus according to claim 10 wherein said welding means
further comprises trimming means for trimming portions of heat
fused material from the joint so that the joint has a relatively
narrow width outward from the textile fabric less than about five
times the predetermined thickness of the textile webs.
12. An apparatus according to claim 8 wherein said feeder means
comprises means for relatively positioning the first and second
textile webs so that respective first longitudinal edges of the
first and second textile webs are generally aligned with each
other.
13. An apparatus according to claim 12 wherein said welding means
comprises an ultrasonic horn and an anvil cooperating therewith to
form the joint from respective first longitudinal edge portions of
the first and second textile webs.
14. An apparatus according to claim 12 wherein said feeder means
further comprises means for positioning a third textile web on the
second textile web so that a longitudinal edge of the third textile
web is generally aligned with a second longitudinal edge of the
second textile web; wherein said welding means further comprises
means for forming a second relatively narrow flexible joint between
the second and third textile webs by heat fusing together adjacent
respective edge portions thereof; and wherein said unfolding frame
comprises means for unfolding the second and third textile webs
about the second joint so that the third textile web lies in the
common plane with the first and second textile webs to further
define the relatively wide textile fabric.
15. An apparatus for forming a convolute roll of a relatively wide
textile fabric by joining together a plurality of textile webs in
side-by-side relation, each of the textile webs comprising heat
fusible nonwoven textile material, said apparatus comprising:
feeder means for positioning a first textile web overlying a second
textile web and advancing the textile webs along a predetermined
path of travel;
ultrasonic welding means positioned along the predetermined path of
travel for forming a relatively narrow flexible joint between the
first and second textile webs by heat fusing together adjacent
portions thereof, said ultrasonic welding means comprising an
ultrasonic horn and an anvil cooperating therewith to form the
joint from the respective adjacent portions of the first and second
textile webs;
an unfolding frame positioned downstream from said ultrasonic
welding means for unfolding the first and second textile webs about
the joint so that the textile webs lie in a common plane to define
the relatively wide textile fabric and so that the relatively
narrow flexible joint extends outwardly from adjacent portions of
the relatively wide textile fabric; and
take-up means positioned downstream from said unfolding frame to
wind the relatively wide textile fabric into successive convolute
wound layers with the relatively narrow flexible joint folded to
lie flat between successive layers so that the successive convolute
wound layers define a cylindrical convolute roll being devoid of a
substantial bulge at the joint.
16. An apparatus according to claim 15 wherein said take-up means
comprises means for winding successive convolute wound layers of
the textile fabric with variations in axial alignment among the
layers so that the relatively narrow joint is offset throughout the
successive convolute wound layers.
17. An apparatus according to claim 15 wherein all of the textile
webs have a same predetermined thickness, and wherein said
ultrasonic welding means further comprises means for pressing
together the adjacent portions of the first and second textile webs
so that the joint has a thickness less than a thickness of the
first and second textile webs.
18. An apparatus according to claim 17 wherein said ultrasonic
welding means further comprises trimming means for trimming
portions of heat fused material at the joint so that the joint has
a relatively narrow width outward from the textile fabric less than
about five times the predetermined thickness of the textile
webs.
19. An apparatus according to claim 15 wherein said feeder means
comprises means for relatively positioning the first and second
textile webs so that respective first longitudinal edges of the
first and second textile webs are generally aligned with each
other.
20. An apparatus according to claim 19 wherein said feeder means
further comprises means for positioning a third textile web on the
second textile web so that a longitudinal edge of the third textile
web is generally aligned with a second longitudinal edge of the
second textile web; wherein said ultrasonic welding means further
comprises means for forming a second relatively narrow flexible
joint between the second and third textile webs by heat fusing
together adjacent respective edge portions thereof; and wherein
said unfolding frame comprises means for unfolding the second and
third textile webs about the second joint so that the third textile
web lies in the common plane with the first and second textile webs
to further define the relatively wide textile fabric.
21. An apparatus for forming a convolute roll of a relatively wide
textile fabric by joining together first, second and third textile
webs in side-by-side relation, each of the textile webs comprising
heat fusible nonwoven textile material, said apparatus
comprising:
feeder means for positioning the first textile web in contact with
the second textile web adjacent a first longitudinal edge thereof,
for positioning the third textile web in contact with the second
textile web adjacent a second longitudinal edge thereof, and for
advancing the textile webs along a predetermined path of
travel;
welding means positioned along the predetermined path of travel for
forming first and second relatively narrow flexible joints between
the first and second textile webs and the third and second textile
webs, respectively, by heat fusing together respective adjacent
portions of the textile webs;
an unfolding frame positioned downstream from said welding means
for unfolding the first and third webs about the respective first
and second joints so that all of the textile webs lie in a common
plane to define the relatively wide textile fabric and so that the
first and second relatively narrow flexible joints extend outwardly
from respective adjacent portions of the relatively wide textile
fabric; and
take-up means positioned downstream from said unfolding frame to
wind the relatively wide textile fabric into successive convolute
wound layers with the first and second relatively narrow flexible
joints folded to lie flat between successive layers so that the
successive convolute wound layers define a cylindrical convolute
roll being devoid of substantial bulges at the joints.
22. An apparatus according to claim 21 wherein said take-up means
comprises means for winding successive convolute wound layers of
the textile fabric with variations in axial alignment among the
layers so that each of the relatively narrow joints is offset
throughout the successive convolute wound layers.
23. An apparatus according to claim 21 wherein all of the textile
webs have a same predetermined thickness, and wherein said welding
means further comprises means for compressing the adjacent portions
of the first and second textile webs and adjacent portions of the
second and third textile webs so that the respective first and
second joints each have a thickness less than the predetermined
thickness of the textile webs.
24. An apparatus according to claim 23 wherein said welding means
comprises trimming means for trimming predetermined portions of
heat fused material at the first and second joints so that each of
the joints has a relatively narrow width of less than about five
times the predetermined thickness of the textile webs.
25. An apparatus according to claim 21 wherein said feeder means
further comprises means for generally aligning a longitudinal edge
of the first textile web with a first longitudinal edge of the
second textile web and for generally aligning a first longitudinal
edge of the third textile web with a second longitudinal edge of
the second textile web.
26. An apparatus according to claim 25 wherein said welding means
comprises a respective ultrasonic horn and an anvil cooperating
therewith to form each of the first second joints from respective
edge portions of the respective textile webs.
Description
FIELD OF THE INVENTION
The present invention relates to the field of equipment and methods
for making textile fabrics, and more particularly, to an apparatus
and method for making a relatively wide textile fabric from a
plurality of textile webs joined together in side-by-side
relation.
BACKGROUND OF THE INVENTION
Many textile manufacturing operations produce side trims of textile
webs, such as nonwoven textile webs used for bedding products.
These side trims are often of first quality nonwoven textile
material, such as polyester or polypropylene. However, these side
trims are typically not sufficiently wide to be readily used for
other textile products. For example, a side trim less than about 60
inches has a relatively low commercial value, while side trims in
the 30 to 40 inch range are quite commonly produced and available,
yet which also have relatively little commercial value. Typical
bedding product related applications use textile fabrics having
widths in the range of 86 to 104 inches, with 96 inches being a
common commercially desired width. Accordingly, the relatively
narrow side trims are often disposed of as waste at an additional
expense to the manufacturer.
Various efforts have been attempted to join or otherwise connect
two or more such side trims into a textile fabric having a
sufficiently large width to be useful in forming bedding products,
such as a backing for a mattress cover. A mattress cover typically
includes a nonwoven textile fabric as the backing, an overlying
layer of fiberfill, and an outer fabric layer or ticking. The
backing layer simply serves to permit quilting of the ticking and
fiberfill together to form an integral unit.
Referring to FIGS. 1-3, a prior attempt by the inventor of the
present invention is explained, wherein the inventor joined
together three side trims, or textile webs 21, 22 and 23, to form a
wider textile fabric using a heat calendaring apparatus 20 (FIG.
1). More particularly, side edges of adjacent textile webs were
overlapped several inches and heated under pressure by suitable
heating means, such as a pair of heated calender rolls 27, to form
overlapping seams or joints 26, thereby joining the adjacent webs
together.
Unfortunately, the overlapped joints 26 represented essentially a
double thickness of material which, when arranged in the plurality
of convolute wound layers, tended to form bulges in the convolute
roll of the textile fabric 25. Moreover, these bulges introduced
biases into the textile fabric which could not be readily removed
upon unwinding of the fabric from the roll and thereby rendered the
biased textile fabric unsuitable for many potential applications,
including the backing layer for a mattress cover. In addition,
polypropylene, a common nonwoven textile material, could not be
used in the heat calendaring process.
SUMMARY OF THE INVENTION
In view of the foregoing background it is therefore an object of
the present invention to provide an apparatus and method for
forming a relatively wide textile fabric by joining a plurality of
textile webs, such as textile side trims, together in side-by-side
relation.
It is another object of the present invention to provide an
apparatus and method for forming a relative wide textile fabric
formed from a plurality of textile webs that may be wound into
convolute roll form without imparting undesirable biases into the
textile fabric and without undesirable bulges at the joints.
These and other objects, features and advantages of the present
invention are provided by an apparatus for forming a relatively
wide textile fabric from a plurality of textile webs wherein the
apparatus includes feeder means for positioning a first, or upper,
textile web overlying a second, or base, textile web and advancing
the textile webs along a predetermined path of travel; welding
means for forming a relatively narrow flexible joint between the
textile webs by heat fusing together adjacent portions thereof; and
an unfolding frame for unfolding the textile webs about the joint
so that the textile webs lie in a common plane to define the
relatively wide textile fabric. More particularly, in order to form
the convolute roll of the relatively wide textile fabric, the
apparatus also preferably includes take-up means positioned
downstream from the unfolding frame to wind the relatively wide
textile fabric into successive convolute wound layers. Accordingly,
the relatively narrow flexible joint is thus folded to lie flat
between successive layers so that the successive convolute wound
layers define a cylindrical convolute roll being devoid of a
substantial bulge at the joint.
As used herein, the terms "textile fabric" or "relatively wide
textile fabric" are used to define the resultant textile product of
joining together a plurality of "textile webs". As would be readily
understood by those skilled in the art, the textile webs and the
textile fabric are formed of the same nonwoven heat fusible textile
material, such as polyester or polypropylene. Commercially
undesirable side trims may thus be joined to provide a commercially
valuable relatively wide textile fabric.
All of the textile webs may have a same predetermined thickness.
The welding means preferably includes means for pressing together
the adjacent portions of the textile webs so that the joint has a
thickness less than the predetermined thickness of the textile
webs. In addition, the welding means also preferably includes
trimming means for trimming portions of heat fused material from
the joint so that the joint has a relatively narrow width outward
from the textile fabric less than about five times the
predetermined thickness of the textile webs.
Another feature of the invention is that the relatively narrow
joint may be axial offset slightly in successive convolute wound
layers by the take-up means. Accordingly, the likelihood of forming
a bulge and imparting undesirable biases in the textile fabric is
further avoided. A random offset may be obtained by the take-up
means in view of the relative narrow width of the joint and the
speed of operation of take-up.
The welding means is preferably provided by an ultrasonic horn
cooperating with an opposing ultrasonic anvil. The feeder means
preferably includes means for relatively positioning the first and
second textile webs so that respective first longitudinal edges of
the first and second textile webs are generally aligned with each
other. Accordingly, the ultrasonic horn and anvil cooperate to form
the joint from respective first longitudinal edge portions of the
textile webs.
The plurality of textile webs joined together may also be three in
a preferred embodiment of the invention. Thus, the feeder means
preferably further includes means for positioning a third textile
web on the second textile web so that a longitudinal edge of the
third textile web is generally aligned with a second longitudinal
edge of the second textile web. In addition, the welding means also
preferably includes means for forming a second relatively narrow
flexible joint between the second and third textile webs by heat
fusing together adjacent respective edge portions thereof. In this
embodiment, the unfolding frame also further includes means for
unfolding the second and third textile webs about the second joint
so that the third textile web lies in the common plane with the
other textile webs to further define the relatively wide textile
fabric.
A method aspect according to the present invention includes the
steps of positioning a first textile web overlying a second textile
web while advancing the first and second textile webs along a
predetermined path of travel; forming a relatively narrow flexible
joint between the textile webs by heat fusing together adjacent
portions thereof as the textile webs are moved along the
predetermined path of travel; and unfolding the thus joined textile
webs about the joint so that the textile webs lie in a common plane
to define the relatively wide textile fabric. The method also
preferably includes the step of winding the relatively wide textile
fabric into successive convolute wound layers with the relatively
narrow flexible joint folded to lie flat between successive layers
so that the successive convolute wound layers define a cylindrical
convolute roll being devoid of a substantial bulge at the joint. As
discussed above, a third textile web may be joined to the second
textile web to form an even wider overall textile fabric.
BRIEF DESCRIPTION O THE DRAWINGS
FIG. 1 is a schematic perspective view of a heat calendaring
apparatus for joining textile webs as in the prior art.
FIG. 2 is an enlarged cross-sectional view of a textile fabric as
in the prior art taken along lines 2--2 of FIG. 1 and as produced
using the prior art apparatus as shown in FIG. 1.
FIG. 3 is a greatly enlarged cross-sectional view of a bulging
portion of textile fabric as in the prior art taken along lines
3--3 of FIG. 1.
FIG. 4 is a perspective view of a convolute roll of the textile
fabric produced using the apparatus and method according to the
present invention.
FIG. 5 is an enlarged cross-sectional view of the textile fabric
taken along lines 5--5 of FIG. 4.
FIG. 6 is a greatly enlarged cross-sectional view of a portion of
the textile fabric taken along lines 6--6 of FIG. 4.
FIG. 7 is a perspective schematic view of first embodiment of the
apparatus according to the invention.
FIG. 8 is an enlarged cross-sectional view taken along lines 8--8
of FIG. 7.
FIG. 9 is a greatly enlarged view of the unfolding frame of the
apparatus according to the invention viewed from the upstream
side.
FIG. 10 is a greatly enlarged view of the unfolding frame of the
apparatus according to the invention viewed from the downstream
side.
FIG. 11 is a perspective view of the unfolding frame of the
apparatus according to the invention with the textile fabric
removed for greater clarity.
FIG. 12 is an exploded view of the unfolding frame as illustrated
in FIG. 11.
FIG. 13 is a cross-sectional view of the unfolding frame as taken
along lines 13--13 of FIG. 11.
FIG. 14 is a perspective view of a first embodiment of a convolute
roll of textile fabric produced using the first embodiment of the
apparatus according to the invention as shown in FIG. 7.
FIG. 15 is a perspective view of a second embodiment of a convolute
roll of textile fabric produced using the second embodiment of the
apparatus according to the invention as shown in FIG. 18.
FIG. 16 is an enlarged schematic perspective view of a portion a
joint and adjacent portion of textile fabric produced by the
apparatus according to the present invention.
FIG. 17 is a greatly enlarged schematic perspective view of a
portion the joint and adjacent portion of textile fabric as shown
in FIG. 16.
FIG. 18 is a perspective schematic view of a second embodiment of
the apparatus according to the invention.
FIG. 19 is an enlarged cross-sectional view taken along lines
19--19 of FIG. 18.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be described more fully hereinafter
with reference to the accompanying drawings, in which preferred
embodiments of the invention are shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
applicant provides these embodiments so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout and prime notation is used to indicate similar
elements of alternate embodiments.
Referring now first to FIGS. 4-8, a first illustrated embodiment of
the apparatus 20 for producing a first embodiment of textile fabric
30 according to the invention is described. The textile fabric 30
includes a plurality of textile webs, such as the medial 31 and two
side webs 32 and 33 in the illustrated embodiment, joined together
in side-by-side relation. A respective joint 35 (FIG. 6) having a
generally strip-like shape joins each pair of adjacent textile
webs. Each joint 35 is formed from edge portions of respective
adjacent webs being heat fused together so that each joint extends
outwardly from a predetermined face of the textile fabric 30. Each
joint 35 preferably extends continuously along an entire length of
the textile webs.
Each of the textile webs 31, 32 and 33 may be provided by
commercially available first quality side trims including a
nonwoven heat fusible textile material. For example, side trims
produced as a result of making a backing layer for a mattress
cover, may typically be available in convolute roll form having
widths less than about 60 inches and more commonly ranging between
about 30 to 40 inches. Thus, the overall width of the textile
fabric 30 is desirably in the range of about 86 to 104 inches, with
96 inches being a commercially preferred width, for example.
All of the textile webs 31, 32 and 33 preferably also include the
same nonwoven heat fusible textile material, such as including
spunbonded or meltblown polyester or polypropylene. Those having
skill in the art will recognize other suitable nonwoven textile
materials. The nonwoven textile material of the webs 31, 32 and 33
also preferably has a relatively soft hand. In addition, the
textile material of the textile webs is preferably relatively
lightweight having a weight in a range between about 1/2 to 2
ounces, and more preferably, in the range of about 1/2 to 1
ounces.
The textile fabric 30 is preferably manufactured and provided to
end users as a convolute roll 40 including a plurality of convolute
wound layers as shown in FIG. 3. The convolute roll 40 may be wound
upon a tubular core 37 and supported on a spindle 38 as would be
readily understood by those skilled in the art. The convolute roll
40 facilitates take-up during the manufacturing process of the
textile fabric 30, permits convenient storage and transportation of
the textile fabric, and facilitates delivery of the textile fabric
into an apparatus of the end user.
As shown in the illustrated embodiment, each of the textile webs
31, 32 and 33 preferably has a respective substantially uniform
width throughout an entire length thereof. As shown perhaps best in
the greatly enlarged view of FIG. 6, each joint 35 lies
substantially flat (FIG. 6) on a respective textile web 31 or 32 in
successive convolute wound layers because of the flexibility of the
joint, and each joint is relatively thin. Accordingly, although the
joint 35 in successive layers is somewhat aligned because of the
uniform width of the textile webs 31, 32 and 33, the convolute
wound layers still define a cylindrical shape for the outer surface
of the convolute roll 40. In other words, the convolute roll 40 is
devoid of a substantial bulge at each joint 35, in sharp contrast
to the heat calendared textile fabric forming a convolute roll 25
as in the prior art (FIGS. 1-3).
The joints 35 according to the invention provide a sufficiently
strong connection between adjacent textile webs, and, moreover,
impart substantially no bias to the convolute roll 40 of the
textile fabric 30. For example, for a backing for a mattress cover,
the strength of the joint 35 need be about only 50% of the strength
of the textile web. The backing layer need only permit quilting or
stitching of the mattress ticking and fiberfill layer. Thus, the
textile fabric 30 according to the invention may readily be used as
a backing for a mattress cover. Those of skill in the art will
readily envision other uses and applications for the relatively
wide textile fabric 30.
Referring briefly now additionally to the greatly enlarged views of
FIGS. 16 and 17, further aspects of the joint 35 and textile webs
31, 32 and 33 are explained. Each joint 35 is flexible and extends
outwardly from the respective textile webs 31 and 32 so that the
joint is readily folded to lie flat on a respective textile web
(FIG. 6). In addition, each textile web 31, 32 and 33 preferably
has a same predetermined thickness t.sub.1, and each joint has a
predetermined width w extending outwardly from the textile webs
being less than about five times the predetermined thickness
t.sub.1 of the textile webs. For example, the predetermined
thickness t.sub.1 of the textile webs may be in the range of about
0.002 to 0.025 inches. Each joint 35 also preferably has a
thickness t.sub.2 less that the predetermined thickness t.sub.1 of
the textile webs.
Each joint 35 has a relatively narrow width w, and the plurality of
convolute wound layers have slight variations in axial alignment.
In addition, the joint 35 may be folded to the left or right and
vary randomly in its direction of fold throughout the entire length
of the textile fabric 30. Accordingly, the joint 35 is randomly
slightly axially offset in the convolute wound layers (FIG. 6)
during the winding or take-up step as described in greater detail
below; thus, producing a somewhat random offset in the joint to
further avoiding any biasing of the textile fabric 30 as occurred
in the heat calendared overlapping seams 24 of the prior art (FIGS.
1-3). The textile fabric 30 according to the present invention is
also described in an application by the present applicant
concurrently filed and entitled "Textile Fabric Formed of a
Plurality of Textile Webs Joined Together in Side-By-Side
Relation", U.S. patent application Ser. No. 08/233,530 filed Apr.
26, 1994, the entire disclosure of which is incorporated herein by
reference.
Referring now to FIGS. 7 through 13, an first embodiment of the
apparatus 50 and for making the first embodiment of the textile
fabric 30 according to the invention is explained. The apparatus 50
is for making the embodiment of the textile fabric 30 including
three textile webs, that is, with a medial or base web 31, and two
side or upper webs 32, 33. The apparatus 50 includes a supply
source 51 for mounting respective rolls of the three textile webs
to permit delivery of the webs. A series of rollers 52 provides a
predetermined path through which the webs 31, 32 and 33 are
advanced as would be readily understood by those skilled in the
art. Stated simply, the supply source 51 and rollers 52 provide
feeder means for relatively positioning the webs and advancing the
webs along a predetermined path of travel.
In a preferred embodiment the base or medial web 31 is wider than
either of the upper webs 32, 33. Accordingly, the two upper webs
32, 33 are readily positioned overlying the base web 31 with
respective left and right edges generally aligned as illustrated by
blocks 49a, 49b.
The three aligned textile webs 31, 32 and 33 are advanced along the
predetermined path of travel to the welding means 54 which also
includes means for trimming the excess material to the relatively
narrow joint 35 between adjacent webs. The trimmed material 67 may
be readily removed by trim remover means 70, such as by
conventional suction nozzles, as would be readily understood by
those skilled in the art.
Referring now more particularly to FIG. 8, the welding means is
preferably provided by an ultrasonic horn 57 and associated
rotating anvil 56 to weld or heat fuse overlapping edge portions of
the textile webs together, while simultaneously trimming off any
excess material. The anvil 56 preferably has a predetermined
contacting surface to simultaneously weld the textile material to
form the joint 35 and cut the trimmed material 67. The anvil 56 is
also preferably downwardly biased to provide a predetermined
pressure. The biasing is illustratively achieved by a pneumatic air
supply 66 and a control valve 65 in communication with a piston 64,
in turn, coupled to the anvil, as would be readily understood by
those skilled in the art. As would also be readily understood by
those skilled in the art, an ultrasonic transducer 61 and booster
or amplifier 62 also preferably cooperate to form the ultrasonic
welding and trimming means. The pneumatically operated piston 64
provides means for pressing together the adjacent portions of the
textile webs so that the joint 35 has a thickness less than a
predetermined thickness of the textile webs 31, 32 and 33. Examples
of ultrasonic welding apparatus can be found in U.S. Pat. Nos.
4,693,771 and 4,534,819 to Payer et al.; U.S. Pat. No. 4,496,407 to
Lowery, Sr. et al.; and U.S. Pat. No. 4,227,959 to Brown, the
entire disclosures of each being incorporated herein by
reference.
The ultrasonic welding and trimming tends to make the joint 35
thinner than the textile webs 31, 32 and 33 as discussed above. The
joint 35 is also somewhat flexible, being formed from the heat
fused edges of the textile webs 31, 32 and 33. Thus, in
freestanding sheet form, the joint 35 may extend outwardly from the
textile fabric, yet be readily folded flat with the respective
textile web portions when wound into successive layers defining the
convolute roll 40.
As also illustrated in FIG. 8, the two side webs 32, 33 may overlap
depending on the length of the respective webs 31, 32 and 33 and
the desired width of the textile fabric 30 produced by the
apparatus 50.
Returning now again to FIG. 7 and additionally to FIGS. 9-13, the
unfolding frame is explained. The unfolding frame includes a fixed
frame member 76 and a pair of triangular shaped wing members 77,
78. The fixed frame member 76 includes side-by-side slots 80, 81 on
an upper portion and cooperating with respective fasteners 82, 83
to facilitate adjusting the relative spacing of the wing members
77, 78 to accommodate different widths of the joined together webs
31, 32 and 33.
The folded joined webs from the welding means 54 enter the
unfolding frame 75 as shown in FIG. 9. The left web 32 as shown in
FIG. 9 engages the lower triangular guide portion of the left wing
member 77 so that the joint 35 aligns with the apex of the
triangular guide portion. Accordingly, the left web 32 is unfolded
while passing through the left wing 77. Similarly, the right web 33
shown in FIG. 9 is unfolded by the right wing member 78 as would be
readily understood by those skilled in the art.
Referring again to FIG. 7, the unfolded textile webs 31, 32 and 33
define the textile fabric 30. Take-up means 90 is positioned
downstream from the unfolding frame 75 to take up the textile
fabric 30 in convolute roll form producing the convolute roll 40 as
discussed extensively above. The take-up means 90 includes a
conventional spindle and a drive motor, not shown, for winding the
textile fabric 30 into a plurality of convolute wound layers.
Because of the relatively narrow width of the joints 35, the joints
are inherently slightly offset in an axial direction by the take-up
means to thereby further prevent a substantial bulge from appearing
on the convolute roll 40. To record the amount of textile fabric 30
accumulated on the convolute roll 40, a conventional yardage
counter 91 may be positioned on the roll as shown in FIG. 7.
Referring now to FIGS. 18, 19 and 15, a second embodiment of the
apparatus 50' is illustrated for forming the second embodiment of
the textile fabric 30' as shown in FIG. 15. Since the second
embodiment of the textile fabric 30' is formed from only two
textile webs 31', 33' the apparatus includes a supply source 51'
including only two rolls of the textile webs. The other elements of
this second embodiment of the apparatus 50' according to the
invention include similar numbers as the above described three-web
embodiment of the apparatus 50. Accordingly, the elements of this
second embodiment of the apparatus 50' will be fully understood by
those skilled in the art without further description.
A method aspect of the present invention is for forming the
relatively wide textile fabric by joining together a plurality of
textile webs in side-by-side relation. For illustration purposes,
reference numerals relating to the second embodiment of the
invention are primarily used to explain the method according to the
invention. The method includes the steps of: positioning a first
textile web 33' overlying a second textile web 31' while advancing
the first and second textile webs along a predetermined path of
travel; forming a relatively narrow flexible joint 35' between the
first and second textile webs by heat fusing together adjacent
portions thereof as the textile webs are moved along the
predetermined path of travel; and unfolding the thus joined first
and second textile webs 33', 31' about the joint 35 so that the
first and second textile webs lie in a common plane to define the
relatively wide textile fabric 30'. The method also preferably
includes the step of winding the relatively wide textile fabric 30'
into successive convolute wound layers with the relatively narrow
flexible joint folded to lie flat between successive layers so that
the successive convolute wound layers define a cylindrical
convolute roll 40' being devoid of a substantial bulge at the
joint.
The step of winding the relatively wide textile fabric also
preferably includes winding the successive convolute layers of the
textile fabric 30' with variations in axial alignment so that the
relatively narrow joint 35' is offset throughout the plurality of
convolute wound layers. In addition, since the first and second
textile webs preferably have a predetermined thickness, the step of
forming the joint further preferably includes pressing together the
adjacent portions of the textile webs so that the joint 35' has a
thickness less than the predetermined thickness of the textile
webs. A trimming step is also preferably performed substantially
simultaneously with the welding step by an ultrasonic horn 57' and
anvil 56' for trimming portions of heat fused textile material at
the joint so that the joint is less than about five times the
predetermined thickness of the textile webs.
The step of positioning the first and second textile webs 31', 33'
further preferably includes relatively positioning the textile webs
so that respective first longitudinal edges of the textile webs are
generally aligned with each other. As would be readily understood
in view of the description relating to the first embodiment of the
apparatus 50 according to the invention, a third web 32 may also be
preferably positioned, welded and unfolded according to the method
of the present invention.
Many modifications and other embodiments of the invention will come
to the mind of one skilled in the art having the benefit of the
teachings presented in the foregoing descriptions and the
associated drawings. For example, while embodiments of the textile
fabric 30, 30' have been illustrated formed with three and two
textile webs, respectively, those of skill in the art will readily
appreciate that a greater number of textile webs may also be joined
together. To do so, multiple passes may be made through the
apparatus as illustrated, for example. Therefore, it is to be
understood that the invention is not to be limited to the specific
embodiments disclosed, and that modifications and embodiments are
intended to be included within the scope of the appended
claims.
* * * * *